Parametric Optimization for Minimizing Surface Roughness in Electrochemical Machining (ECM) by Full Factorial Design

Nagham Ghanim; Shukry   Hammed; Saja  Salahuddin

doi:10.71229/sj2cff95

Authors

Nagham Ghanim Ghazi Construction and Projects Department, University of Technology, Baghdad, Iraq
Shukry Hammed Aghdeab Nanotechnology and Advanced Materials Research Center, University of Technology, 10066, Baghdad, Iraq.
Saja Salahuddin Qaddoori Fuel and Energy Engineering Techniques Department, Middle Technical University, 10098, Baghdad, Iraq.

DOI:

https://doi.org/10.71229/sj2cff95

Keywords:

Anova , Electrolyte , Minitab , Nontraditional machining , Statistical modeling

Abstract

Achieving a high-quality machined surface is the real challenge in machining processes, but not with electrochemical machining (ECM). This research studied surface roughness as an indicator of machining accuracy and functional performance of a workpiece of high-speed steel AISI M2 using a tool of copper in an electrolyte of sodium chloride (NaCl), combined with water. It aimed to get a very smooth surface that can be used in precision industries such as medicine, aviation, turbine blades, and injection molds, thus reducing friction between parts, improving the coating and lubricating properties, and increasing thermal and electrical conductivity. Studying surface roughness can resolve several industrial problems related to unevenness or microscopic irregularity, as well as mechanical deformations on the workpiece surface, and loss of accuracy of dimensions. This was accomplished practically through experiments, varying the values of operating conditions, including a voltage of (10, 20, and 30 V), an electrolyte concentration of (20, 40, and 60 g/l), and a gap of (0.1, 0.2, and 0.3 mm). In addition, statistic was used to describe the relationship between operating conditions and surface roughness by creating a mathematical model in Minitab software. The design of experiments was created by a full factorial design that analysed the main effects of the operating conditions. The results showed that a smoother surface with less roughness was obtained with a value of 0.3201µm, making ECM a very good finishing process. Voltage had a high effect with 93.8% contribution, followed by electrolyte concentration with 3.9% contribution, while gap did not have a significant effect. The operating conditions that gave lower surface roughness were A voltage of 10V, an electrolyte concentration of 20g/l, and a gap of 0.3mm.

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